Institut für Elektroprozesstechnik

The Scope for Electricity & Carbon Saving in the EU through the use of

EPM Technologies

Prof. Dr.-Ing. Egbert Baake

Dipl. Wirtsch.-Ing. Bernhard Ubbenjans

Institute of Electrotechnology

2

Scope of the Project

Electromagnetic processing of materials (EPM) provides significant opportunities for

saving primary energy and reducing carbon emissions in industrial thermal

processes. The use of electricity for industrial thermal processes has a current

market share of around 10% in Europe and is divided in numerous different

applications and industrial branches, where today the share between fossil fuel and

electricity used as the end energy carrier is absolute different. All applications and

processes play a different role and offer different potentials in terms of saving of

primary energy and reducing of greenhouse gas emission. Potentially, electricity can

replace up to 100% of other energy carriers currently used for process heat. As the

average primary energy factor (PEF) gradually decreases from 2.5 currently, to 1 for

a 100% renewable electricity system, the benefits of EPM will gradually increase. The

CO2-emission factor will decrease as well which means a decrease in greenhouse

gas emissions. Moreover, as the electricity system is decarbonising rapidly, EPM

technologies will increase with time. A very important background and basic for this

analysis is the forecast of the future energy supply.

The paper demonstrates the features, benefits and advantages of processes and

technologies for electromagnetic processing of materials (EPM). For the time horizon

from now to the year 2050 a transition scenario is developed and described. In this

scenario the industrial processes are gradually switched from the actual situation to a

situation with 100% electrically operated industrial processes. The scenario will take

into account both the most energy intensive industrial thermal processes, which could

be replaced by electrothermal technologies and offer obviously the biggest future

potential in terms of saving of primary energy and reducing of carbon emissions but

also lower energy intensive heating processes, which are used in many different

industrial branches and require a more detailed investigation.

3

Executive Summary

The work in hand makes clear that a switching of fuel operated industrial processes

to electro-thermal processes offers big potentials for saving of primary energy and

CO2-emission.

A very important background and basic for this analysis is the forecast of the future

energy supply in Europe. In this investigation the main focus is set on the

development of the primary energy factor (PEF) and CO2-emission factor which is

presented for each year till to 2050. It can be expected that the primary energy factor

will decrease from currently 2.5 to 1 due to the increasing supply by renewable

energies. The CO2-emission factor will decrease as well, which means a decrease in

greenhouse gas emissions.

In this work the savings of CO2-emissions are calculated for a variety of different

energy-intensive industrial processes. To calculate the savings three different

switching scenarios are compared.

• The first is the reference scenario, which implies no switching to electrical

processes.

• The second scenario, called linear scenario, assumes a linear increase of

electrical processes to 100% in the year 2050.

• The shock scenario is the third one and implies an increase from the current

situation to 100% between the years 2020 and 2025.

In 2009 the overall energy consumption of the European industry reached a value of

3,133,762 GWh. Altogether five energy intensive industrial branches have been

analysed with the help of case studies. These five industry sectors ordered by the

final energy demand in 2009 are the chemical industry with 585,896 GWh, the iron

and steel industry with 514,848 GWh, the glass, pottery and building material industry

with 424,832 GWh, the paper and printing industry with 384,116 GWh and the non-

ferrous metal industry with 103,681 GWh (compare with Fig. 5). These selected five

industry sectors cover about 70 % of the overall energy consumption of the European

industry.

4

Table 1 summarizes the share of the calculated final energy demand on the overall

final energy demand of the five different branches. The table gives an overview how

much the case studies cover the overall energy demand.

Table 2 summarizes the savings respectively additional amounts of final energy,

primary energy and CO2-emission that can be achieved.

Branch Industry sector

Calculated final energy demand

in 2010

Final energy demand of the branch

Share

Chemical Plastic 110,500

Sum 110,500 585,896 19 %

Iron & steel Steel 434,923

Grey iron 10,972

Sum 445,904 514,848 87 %

Glass, pottery &

building materials Glass

55,500

Roof tile 10,493

Brick 28,976

Cement 289,907

Lime 36,400

Sum 421,275 424,832 99 %

Paper & printing Paper 200,299

Sum 200,299 384,116 52 %

NF metals Aluminum 2,774

Sum 2,774 103,681 3 %

Table 1: Share of the calculated final energy demands on the overall energy demand of the five different branches.

5

Savi

ng p

oten

tials

for u

sing

the

shoc

k sc

enar

io C

O2-

emis

sion

Mill

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tons

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0

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2,20

4.6

205.

4

508.

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18.3

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6.3

Prim

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311.

7

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Fina

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77.9

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0.8

Savi

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9

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3.5

150.

2

374.

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5.0

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*

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Gre

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Roo

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Sum

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Non

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met

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Table 2: Savings of final energy, primary energy and CO2-emission for the two the different industry sectors for both switching scenarios (* Negative numbers imply an additional effort).

6

Table of contents

1. Introduction ........................................................................................................ 8

2. Primary energy factor & CO2 emission factor.................................................. 9

3. Energy consumption of the European industry ............................................ 12

3.1 Energy consumption divided by industry sectors ....................................... 12

3.1.1 Iron & steel industry ......................................................................................... 14

3.1.2 Non-ferrous metal industry ............................................................................. 15

3.1.3 Chemical industry ............................................................................................ 16

3.1.4 Glass, pottery & building material Industry .................................................. 17

3.1.5 Ore-extraction industry ................................................................................... 18

3.1.6 Food, drink & tobacco industry ...................................................................... 19

3.1.7 Textile, leather & clothing industry ................................................................ 20

3.1.8 Paper and printing ........................................................................................... 21

3.1.9 Transport equipment ....................................................................................... 22

3.1.10 Machinery ......................................................................................................... 23

3.1.11 Wood and wood products ............................................................................... 24

3.1.12 Construction ..................................................................................................... 25

3.2 Energy consumption divided by energy supplies ....................................... 26

3.2.1 Hard coal ........................................................................................................... 27

3.2.2 Coke ................................................................................................................... 28

3.2.3 Lignite, Peat and Brown coal briquettes ...................................................... 29

3.2.4 Petroleum products ......................................................................................... 30

3.2.5 Natural gas and derived gas .......................................................................... 31

3.2.6 Renewable energy ........................................................................................... 32

3.2.7 Other fuels ........................................................................................................ 33

3.2.8 Derived heat ..................................................................................................... 34

3.2.9 Electrical power ................................................................................................ 35

4. Case studies for the five most energy-intensive industry sectors in the EU-27 ............................................................................................................... 36

4.1 Three different scenarios .................................................................................... 37

7

4.2 Theoretical saving potential for the five most energy-intensive industry sectors of the EU-27 ............................................................................................. 38

4.3 Iron & steel industry ............................................................................................. 42

4.3.1 Steel production ............................................................................................... 42

4.3.2 Casting grey iron .............................................................................................. 46

4.4 Non-ferrous metal industry ................................................................................ 50

4.4.1 Casting copper ................................................................................................. 50

4.4.2 Casting aluminum ............................................................................................ 51

4.5 Chemical industry ................................................................................................. 54

4.5.1 Plastic production ............................................................................................ 54

4.6 Glass, pottery and building materials ............................................................. 57

4.6.1 Glass industry ................................................................................................... 57

4.6.2 Brick industry .................................................................................................... 61

4.6.3 Roof tile industry .............................................................................................. 64

4.6.4 Cement industry ............................................................................................... 67

4.6.5 Lime industry .................................................................................................... 70

4.7 Paper and printing ................................................................................................ 73

5. Conclusion .............................................................................................................. 77

8

1. Introduction

The aim of this work is the formulation of a position report that demonstrates the

benefits and advantages of processes and technologies for electromagnetic

processing of materials (EPM) in Europe (EU-27). For the time horizon from now to

the year 2050 a transition scenario is developed. In this scenario the industrial

processes are gradually switched from the actual situation to a situation with 100%

electrically operated industrial processes. The scenario will take into account both the

most energy intensive industrial thermal processes, which could be replaced by

electro-thermal technologies and offer obviously the biggest future potential in terms

of saving of primary energy and reducing of carbon emissions but also lower energy

intensive heating processes, which are used in many different industrial branches

and require a more detailed investigation.

Very important for this analysis is the forecast of the future energy supply in

Europe. In this work the main focus is set on the development of the primary energy

factor and CO2-emission factor which will be presented for every year up to 2050. It

can be expected that the primary energy factor will decrease from 2.5 currently to 1

due to the increasing supply by renewable energies. The CO2-emission factor will

decrease as well which means a decrease in greenhouse gas emissions. In this work

the savings of CO2-emissions will be calculated for a variety of different energy-

intensive industrial processes. To calculate the savings three different switching

scenarios are compared. The first is the reference scenario, which implies no

switching to electrical processes. The second scenario, called linear scenario,

assumes a linear increase of electrical processes to 100% in the year 2050. The

shock scenario is the third one and implies an increase from the current situation to

100% between the years 2020 and 2025.

9

2. Primary energy factor & CO2 emission factor

For the evaluation of the advantages of the energy switching it is important to know

who much primary energy and CO2 –emissions can be saved with this strategy. For

that it is important to know the primary energy factor and the CO2 emission factor for

each energy carrier.

The primary energy factor and the CO2-emission factor for fossil fuels have been

investigated in different studies1. The factors used in this work are listed in Table 3.

Primary energy factor

CO2 –emission factor

[g/kWh]

Hard coal 1.071811361 406

Coke 1.114827202 473

Lignite 1.038421599 413

Petroleum products 1.095290252 301

Natural gas 1.072961373 227

Table 3: Primary energy factors and CO2-emission factors for different fossil energy carriers.

The factors of primary energy and CO2 –emissions for electrical power depend on the

composition of the energy mix in Europe. For that the forecast of the energy supply in

Europe is a crucial factor of this work. With an increasing share of renewable energy

carrier on the energy mix in Europe both factors will decrease. The development of

the primary energy factor and the CO2 -emission factor from now to the year 2050 will

be used to calculate the possible savings of primary energy and CO2 – emissions in

Europe. The primary energy factor is calculated by dividing the development of the

gross electricity generation by the primary energy used for the gross electricity

generation. The estimated development of the gross electricity production in Europe

is pictured in Fig. 1 and the estimated primary energy that is used for this gross

1 E. Baake, U. Jörn, A. Mühlbauer. 1996. Energiebedarf und CO2-Emission industrieller Prozeßwärmeverfahren. Essen : VULKAN VERLAG, 1996. 3-8027-2912-9.

10

energy generation can be seen in Fig. 2. In Fig. 3 the development of the calculated

primary energy factor is shown.

Fig. 1: Estimated gross electricity generation in the EU-27 in 1000 TWh/year divided by energy carrier2

Fig. 2: Estimated primary energy used for the gross electricity generation in the EU-27 in EJ/year divided by energy carrier2

2 Wissenschaftlicher Beirat der Bundesregierung Globale Umweltveränderungen (WBGU). 2011. Hauptgutachten Welt im Wandel Gesellschaftsvertrag für eine Große Transformation. Berlin : s.n., 2011. ISBN 978-3-936191-36-3.

11

Fig. 3: Primary energy faktor from the year 2005 to 2050

The CO2 -emission factor for electricity is calculated from the estimated use of

primary energy in Fig. 2 taking the single CO2 -emission factors of all the different

contained energy carriers into account. The estimated CO2 -emission factor for

producing electricity in the EU-27 can be seen in Fig. 4.

Fig. 4: CO2 - emission faktor from the year 2005 to 2050 in g/kWh

12

3. Energy consumption of the European industry

3.1 Energy consumption divided by industry sectors

The energy consumption of the European industry reached a value of

3,133,762 GWh in the year 2009. The industry can be split up into 12 different

sectors. They are:

• Iron & steel industry

• Non-ferrous metal industry

• Chemical industry

• Glass, pottery & building material industry

• Ore-extraction industry

• Food, drink & tobacco industry

• Textile, leather & clothing industry

• Paper and printing

• Transport equipment

• Machinery

• Wood and wood products

• Construction

The share and the amount of every industry sector can be seen in Fig. 5.

13

Fig. 5: Final energy consumption of the EU-27 industry in 2009 divided by industry sectors (Sum: 3,133,762 GWh )3

3 Eurostat - European Commission. 2011. Energy Balance Sheets — 2008-2009. Luxembourg : Publications Office of the European Union, 2011.

14

3.1.1 Iron & steel industry

The energy consumption of the iron & steel industry in the EU-27 reaches a value of

514,848 GWh in the year 2009 as already shown in Fig. 5. So the iron & steel

industry is the sector with the second highest energy consumption in Europe after the

chemical industry. The distribution on a percentage basis to the different energy

carriers can be seen in Fig. 6. It is noticeable that coke is the most important energy

carrier with a share of 30 %. This can be explained with the need of coke for the blast

furnace to produce raw iron. Other important energy carriers are gas (30 %),

electrical power (21 %) and hard coal (13 %).

Fig. 6: Final energy consumption in the Iron & steel industry of the EU-27 in 2009 (Sum: 514,848 GWh)3

15

3.1.2 Non-ferrous metal industry

The energy consumption of the non-ferrous metal industry in the EU-27 reaches a

value of 103,681 GWh in the year 2009 as already shown in Fig. 5. The distribution

on a percentage basis to the different energy carriers can be seen in Fig. 7. It is

interesting that electrical energy is the most important energy carrier for this energy

sector by far. This can be explained be the high amount of electrical processes that

already exist in this sector. Typical processes in this field are melting with the

induction channel furnace and electrolyzing. The second considerable energy carrier

is gas with an amount of 26 %.

Fig. 7: Final energy consumption in the non-ferrous metal industry of the EU-27 in 2009 (Sum: 103,681 GWh) 3

16

3.1.3 Chemical industry

The energy consumption of the chemical industry in the EU-27 reaches a value of

585,896 GWh in the year 2009 as already shown in Fig. 5. So the chemical industry

is the sector with the highest energy consumption in Europe. The distribution on a

percentage basis to the different energy carriers can be seen in Fig. 8. The most

important energy carrier is gas with 33 %. It is followed by electrical energy with

30 %. Other important energy carriers are petroleum products (15 %) and derived

heat (14 %).

Fig. 8: Final energy consumption in the chemical industry of the EU-27 in 2009 (Sum: 585,896 GWh) 3

17

3.1.4 Glass, pottery & building material Industry

The energy consumption of the glass, pottery and building material industry in the

EU-27 reaches a value of 424,832 GWh in the year 2009 as already shown in Fig. 5.

This industry sector is the sector with the third highest energy consumption in

Europe. The distribution on a percentage basis to the different energy carriers can be

seen in Fig. 9. The most important energy carrier is gas with 36 %. It is followed by

petroleum products with 26 %. Other important energy carriers are electrical energy

(17 %) and also hard coal (9 %).

Fig. 9: Final energy consumption in the glass, pottery and building material industry of the EU-27 in 2009 (Sum: 424,832 GWh) 3

18

3.1.5 Ore-extraction industry

The energy consumption of the ore-extraction industry in the EU-27 reaches a value

of 31,285 GWh in the year 2009 as already shown in Fig. 5. This industry sector has

a relatively low level of energy consuming in Europe. The distribution on a

percentage basis to the different energy carriers can be seen in Fig. 10. The most

important energy carrier is electrical energy with 45 %. It is followed by petroleum

products with 26 % and gas with 17 %.

Fig. 10: Final energy consumption in the ore-extraction industry of the EU-27 in 2009 (Sum: 31,285 GWh) 3

19

3.1.6 Food, drink & tobacco industry

The energy consumption of the food, drink and tobacco industry in the EU-27

reaches a value of 319,116 GWh in the year 2009 as already shown in Fig. 5. This

industry sector has a relatively high level of energy consuming in Europe. The

distribution on a percentage basis to the different energy carriers can be seen in

Fig. 11. The most important energy carrier is gas with 41 %. It is followed by electrical

energy with 34 % and petroleum products with 11 %.

Fig. 11: Final energy consumption in the food, drink and tobacco industry of the EU-27 in 2009 (Sum: 319,116 GWh) 3

20

3.1.7 Textile, leather & clothing industry

The energy consumption of the textile, leather and clothing industry in the EU-27

reaches a value of 55,906 GWh in the year 2009 as already shown in Fig. 5. This

industry sector has a relatively low level of energy consuming in Europe. The

distribution on a percentage basis to the different energy carriers can be seen in

Fig. 12. The most important energy carrier is gas with 44 %. It is followed by electrical

energy with 39 % and petroleum products with 11 %.

Fig. 12: Final energy consumption in the textile, leather and clothing industry of the EU-27 in 2009 (Sum: 59,906 GWh) 3

21

3.1.8 Paper and printing

The energy consumption of the paper and printing industry in the EU-27 reaches a

value of 384,116 GWh in the year 2009 as already shown in Fig. 5. This industry

sector is the sector with the fourth highest energy consumption in Europe. The

distribution on a percentage basis to the different energy carriers can be seen in Fig.

13. The most important energy carriers are renewable energies with 32 %. It is

followed by electrical energy with 32 % and gas 22 %.

Fig. 13: Final energy consumption in the paper and printing industry of the EU-27 in 2009 (Sum: 384,116 GWh) 3

22

3.1.9 Transport equipment

The energy consumption of the transport equipment industry in the EU-27 reaches a

value of 90,877 GWh in the year 2009 as already shown in Fig. 5. This industry

sector has a relatively low level of energy consuming in Europe. The distribution on a

percentage basis to the different energy carriers can be seen in Fig. 14. The most

important energy carrier is electrical energy with 53 %. It is followed by gas with 32 %

and derived heat with 8 %.

Fig. 14: Final energy consumption in the transport equipment industry of the EU-27 in 2009 (Sum: 90,877 GWh) 3

23

3.1.10 Machinery

The energy consumption of the machinery industry in the EU-27 reaches a value of

196,268 GWh in the year 2009 as already shown in Fig. 5. The distribution on a

percentage basis to the different energy carriers can be seen in Fig. 15. The most

important energy carrier is electrical energy with 48 %. It is followed by gas with 39 %

and petroleum products with 10 %.

Fig. 15: Final energy consumption in the machinery industry of the EU-27 in 2009 (Sum: 196,268 GWh) 3

24

3.1.11 Wood and wood products

The energy consumption of the wood and wood products industry in the EU-27

reaches a value of 95,680 GWh in the year 2009 as already shown in Fig. 5. This

industry sector has a relatively low level of energy consuming in Europe. The

distribution on a percentage basis to the different energy carriers can be seen in Fig.

16. The most important energy carriers are renewable energies with 56 %. It is

followed by electrical energy with 26 %

Fig. 16: Final energy consumption in the wood and wood product industry of the EU-27 in 2009 (Sum: 95,680 GWh) 3

25

3.1.12 Construction

The energy consumption of the construction industry in the EU-27 reaches a value of

71,234 GWh in the year 2009 as already shown in Fig. 5. This industry sector has a

relatively low level of energy consuming in Europe. The distribution on a percentage

basis to the different energy carriers can be seen in Fig. 17. The most important

energy carriers are petroleum products with 55 %. It is followed by electrical energy

with 25 % and gas with 17 %.

Fig. 17: Final energy consumption in the construction industry of the EU-27 in 2009 (Sum: 71,234 GWh) 3

26

3.2 Energy consumption divided by energy source In Fig. 18 the final energy of the industry in the EU-27 is presented divided by energy

supplies. The sum of the final energy is the same like in Fig. 5 and has a value of

3,133,762 GWh. It can be seen that electrical power has already the biggest share

on the final energy consumption with 31 %. The second important energy carrier is

gas with 30 %. It is followed by petroleum products with 14 %, renewable energy with

7 %, derived heat with 6 % and coke and hard coal with each 5 %. The other two

energy carriers lignite, peat and brown coal briquettes and other have each 1 %.

Fig. 18: Final energy consumption of the EU-27 industry in 2009 divided by energy carrier (Sum: 3,133,762 GWh ) 3

27

3.2.1 Hard coal

The energy consumption of hard coal in the EU-27 reaches a value of 160,924 GWh

in the year 2009 as already shown in Fig. 18. This industry sector has a relatively low

level of energy consuming in Europe. The distribution on a percentage basis to the

different industry sectors can be seen in Fig. 19. The iron and steel industry is the

most important industry sector with a share of 43 %. It is followed by the glass,

pottery and building material sector with 24 %, the chemical industry with 14 % and

the food, drink and tobacco industry with 9 %.

Fig. 19: Final energy consumption in the industry of the EU-27 covered by hard coal in 2009 (Sum: 160,924 GWh) 3

28

3.2.2 Coke

The energy consumption of coke in the EU-27 reaches a value of 165,693 GWh in

the year 2009 as already shown in Fig. 18. This industry sector has a relatively low

level of energy consuming in Europe. The distribution on a percentage basis to the

different industry sectors can be seen in Fig. 20. It is remarkable that 94 % of the

energy is used by the iron and steel industry. Coke is needed for the blast furnace to

produce raw iron. Other industry sectors do not have high coke consumptions.

Fig. 20: Final energy consumption in the industry of the EU-27 covered by coke in 2009 (Sum: 165,693 GWh) 3

29

3.2.3 Lignite, Peat and Brown coal briquettes

The energy consumption of lignite, Peat and Brown coal briquettes in the EU-27

reaches a value of 30,354 GWh in the year 2009 as already shown in Fig. 18. This

industry sector has a relatively low level of energy consuming in Europe. The

distribution on a percentage basis to the different industry sectors can be seen in Fig.

21. The chemical industry is the most important industry sector with a share of 38 %.

It is followed by the glass, pottery and building material sector with 37 % and the

paper and printing industry with 15 %.

Fig. 21: Final energy consumption in the industry of the EU-27 covered by lignite, peat and brown coal briquettes in 2009 (Sum: 30,354 GWh) 3

30

3.2.4 Petroleum products

The energy consumption of petroleum products in the EU-27 reaches a value of

428,600 GWh in the year 2009 as already shown in Fig. 18. This energy carrier is the

sector with the third highest energy consumption in Europe. The distribution on a

percentage basis to the different industry sectors can be seen in Fig. 22. The glass,

pottery and building material industry is the most important industry sector with a

share of 31 %. It is followed by the chemical industry sector with 24 %, the

construction industry with 11 % and the food drink and tobacco industry with 10 %

Fig. 22: Final energy consumption in the industry of the EU-27 covered by crude oil and petroleum products in 2009 (Sum: 428,600 GWh) 3

31

3.2.5 Natural gas and derived gas

The energy consumption of natural and derived gas in the EU-27 reaches a value of

936,320 GWh in the year 2009 as already shown in Fig. 18. This energy carrier is the

sector with the second highest energy consumption in Europe. The distribution on a

percentage basis to the different industry sectors can be seen in Fig. 23. Close to

every industry sector uses gas as an energy carrier for their production. The biggest

share has the chemical industry with 22 %. It is followed by the iron and steel industry

and the glass, pottery and building material industry with each 17 %. Other important

industry sectors using gas are the food, drink and tobacco industry with 15 %, the

paper and printing industry with 9 % and the machinery industry with 8 %.

Fig. 23: Final energy consumption in the industry of the EU-27 covered by natural and derived gas in 2009 (Sum: 936,320 GWh) 3

32

3.2.6 Renewable energy

The energy consumption of renewable energies in the EU-27 reaches a value of

228,623 GWh in the year 2009 as already shown in Fig. 18. Energy carrier gets more

and more important. Renewable energies are already the fourth most important

energy carrier in the European industry. The distribution on a percentage basis to the

different industry sectors can be seen in Fig. 24. The biggest share by a long way

has the paper and printing industry with 57 %. It is followed by the wood and wood

products industry with 25 % and the glass, pottery and building material industry and

food, drink and tobacco industry with each 7 %.

Fig. 24: Final energy consumption in the industry of the EU-27 covered by renewable energies in 2009 (Sum: 228,623 GWh) 3

33

3.2.7 Other fuels

The energy consumption of other fuels in the EU-27 reaches a value of 24,516 GWh

in the year 2009 as already shown in Fig. 18. This energy carrier has the lowest

energy consumption in Europe. The distribution on a percentage basis to the different

industry sectors can be seen in Fig. 25. The biggest share has the machinery

industry with 69 %. It is followed by the chemical industry with 21 %.

Fig. 25: Final energy consumption in the industry of the EU-27 covered by other fuels in 2009 (Sum: 24,516 GWh) 3

34

3.2.8 Derived heat

The energy consumption of derived heat in the EU-27 reaches a value of

173,287 GWh in the year 2009 as already shown in Fig. 18. This industry sector has

a relatively low level of energy consuming in Europe. The distribution on a

percentage basis to the different industry sectors can be seen in Fig. 26. The biggest

share has the chemical industry with 55 %. It is followed by the paper and printing

industry with 15 %. Beside this two industry sectors close to every other sector uses

derived heat as well.

Fig. 26: Final energy consumption in the industry of the EU-27 covered by derived heat in 2009 (Sum: 173,287 GWh) 3

35

3.2.9 Electrical power

The energy consumption of electrical energy in the EU-27 reaches a value of

980,994 GWh in the year 2009 as already shown in Fig. 18. This energy carrier is the

sector with the highest energy consumption in Europe. The distribution on a

percentage basis to the different industry sectors can be seen in Fig. 27. Every

industry sector uses electrical energy as an energy carrier for their production. The

biggest share has the chemical industry with 20 %. It is followed by the paper and

printing industry with 14 % and the iron and steel industry and the food, drink and

tobacco industry with each 12 %. Other important industry sectors with high

consumption are the machinery industry with 11 %, the glass, pottery and building

material industry with 8%, the paper and printing industry with 7 % and the transport

equipment with 6 %.

Fig. 27: Final energy consumption in the industry of the EU-27 covered by electrical energy in 2009 (Sum: 980,994 GWh) 3

36

4. Case studies for the five most energy-intensive industry sectors in the EU-27

In this chapter the saving potential of primary energy and CO2 –emissions is

calculated for different industrial products. Therefore the five most energy-intensive

industry sectors are investigated in detail. These five most energy-intensive industry

sectors are:

• Iron & steel industry

• Non-ferrous metal industry

• Chemical industry

• Glass, pottery and building materials

• Paper and printing

Typical products out of every industry sector are investigated in form of case studies.

It is assumed that the demands of these products are kept constant until 2050. For

every product the demand of final energy, primary energy and CO2 –emissions is

calculated for every year and for three different switching scenarios. Furthermore the

integrated savings of final energy, primary energy and CO2 –emissions are

presented. The three different switching scenarios are described in chapter 4.1. In

chapter 4.2 the theoretical saving potential of the five most energy-intensive industry

sectors is calculated. Afterwards the case studies for these five industry sectors are

presented in the chapters 4.3 to 4.7.

37

4.1 Three different scenarios

In the analysis of the case studies three different switching scenarios will be

compared with each other. The first scenario is that there will be no change. This is

called “reference scenario”. The second scenario assumes that there will be a linear

switching from the current situation to a status with 100% electrical power application.

This case is called “linear scenario”. The third instance is that we assume a complete

switching inside of five years from 2020 to 2025. Within these five years the share of

the electrical power use is linearly increased from the current situation to 100%. This

scenario is called “shock scenario”. A graph of the share of electrical power for the

three different scenarios is shown in Fig. 28. The graphics with the integrated savings

in the chapters 4.2 to 4.7 show the savings for the linear and shock scenario instead

of taking the reference scenario.

Fig. 28: Share of electrical power for the three different scenarios from the current

situation in the year 2010 up to a situation with 100% electrical power in the year

2050

38

4.2 Theoretical saving potential for the five most energy-intensive industry sectors of the EU-27

In this chapter the theoretical saving potential is analyzed. Therefore it is assumed

that all processes of the five most energy-intensive industry sectors will be replaced

by electrical processes for 100 %. In the following pictures the cumulative savings of

primary energy and CO2 –emissions for these industry sectors are shown.

Fig. 29: Theoretical cumulative savings potential of primary energy for selected processes in the iron & steel industry sector of the EU-27

Fig. 30: Theoretical cumulative savings potential of CO2-emissions for selected processes in the iron & steel industry sector of the EU-27

-18.000

-16.000

-14.000

-12.000

-10.000

-8.000

-6.000

-4.000

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2010

2015

2020

2025

2030

2035

2040

2045

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J]

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Shock scenario

0

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0.000

0.500

1.000

1.500

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3.000

2010

2015

2020

2025

2030

2035

2040

2045

2050

Savi

ng o

f CO

2 em

issi

on [M

io t]

Linear scenario

Shock scenario

0

-500

500

39

Fig. 31: Theoretical cumulative savings potential of primary energy for selected processes in the non-ferrous metal industry sector of the EU-27

Fig. 32: Theoretical cumulative savings potential of CO2-emissions for selected processes in the non-ferrous metal industry sector of the EU-27

Fig. 33: Theoretical cumulative savings potential of primary energy for selected processes in the chemical industry sector of the EU-27

-1.800

-1.600

-1.400

-1.200

-1.000

-0.800

-0.600

-0.400

-0.200

0.000

2010

2015

2020

2025

2030

2035

2040

2045

2050

Savi

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J]

Linear scenario

Shock scenario

0

-200

-400

-600

-800

-14.000

-12.000

-10.000

-8.000

-6.000

-4.000

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2010

2015

2020

2025

2030

2035

2040

2045

2050

Savi

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J]

Linear scenario

Shock scenario

0

40

Fig. 34: Theoretical cumulative savings potential of CO2-emissions for selected processes in the chemical industry sector of the EU-27

Fig. 35: Theoretical cumulative savings potential of primary energy for selected processes in the glass, pottery and building materials industry sector of the EU-27

Fig. 36: Theoretical cumulative savings potential of CO2-emissions for selected processes in the glass, pottery and building materials industry sector of the EU-27

-200

0

200

400

600

800

1000

1200

1400

2010

2015

2020

2025

2030

2035

2040

2045

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Linear scenario

Shock scenario

1,400

1,200

1,000

-14.000

-12.000

-10.000

-8.000

-6.000

-4.000

-2.000

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2010

2015

2020

2025

2030

2035

2040

2045

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Savi

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J]

Linear scenario

Shock scenario

0

-200

0

200

400

600

800

1000

1200

1400

1600

2010

2015

2020

2025

2030

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issi

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io t]

Linear scenario

Shock scenario

1,000

1,200

1,400

1,600

41

Fig. 37: Theoretical cumulative savings potential of primary energy for selected processes in the paper and printing industry sector of the EU-27

Fig. 38: Theoretical cumulative savings potential of CO2-emissions for selected processes in the paper and printing industry sector of the EU-27

-1400

-1200

-1000

-800

-600

-400

-200

0

2010

2015

2020

2025

2030

2035

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J]

Linear scenario

Shock scenario

42

4.3 Iron & steel industry

4.3.1 Steel production

In the year 2009 the 27 European states produced more than 139 Million tons of

steel4. It is assumed that the total demand of steel per year in Europe will be constant

until 2050. In principle there exist two ways for the production of steel in Europe. The

first is the production of crude iron in a blast furnace that is subsequently transformed

into steel using an oxygen blown converter. This is the classical route of steel

production and has a share of 56 % on the over-all output4. The second technique is

the production of steel in furnaces operated with electrical power, especially electric

arc furnaces. This furnace can be operated with steel scrap as well as with direct

reduced iron. The share of the electric arc furnace on the cumulated steel production

is about 44 %4.

The feedstock for the blast furnace is iron ore that is reduced to iron with the help of

coke and lime. This is a very energy intensive process. For the fabrication of 1 ton of

crude iron a typical blast furnace needs 650 kg of iron ore and 907 kg of sinter.

Additionally 475 kg of coke, 800 MJ of electrical energy and 2.5 kg of scrap are

used5. 18 % of the blast furnace gas is recovered for the production of coke5. Directly

after the furnace process the liquid iron is transformed into steel in an oxygen blown

converter. Nearly pure oxygen is pumped through the melt to reduce the high amount

of carbon inside the volume. The oxygen converter needs for 1 ton of steel approx.

925 kg of raw iron, 50 m3 of oxygen and 220 kg of scrap to cool down the melt during

the process6.

4 World Steel Association (worldsteel). July 2011. Steel Statistical Yearbook 2011. Brussels : s.n., July 2011.

5 K., Wegener-Giebel. 1996. Bewertung des Energiebedarfs und der CO2-Emission konkurrierender Verfahren zur Eisen- und Stahlproduktion. Diplomarbeit. Universität Hannover : s.n., 1996. 6 Fraunhofer-Institut für Systemtechnik und Innovationsforschung ISI. August 2004. Werkstoffeffizienz - Einsparpotenziale bei Herstellung und Verwendung energieintensiver Grundstoffe. s.l. : Fraunhofer IRB Verlag, August 2004.

43

The electric arc furnace is charged with scrap or optional with direct reduced ore. The

volume is melted down through a powerful electric arc that is burning between the

carbon electrodes and the charged material. For the production of 1 ton of steel the

arc furnace has to be filled with approx. 1080 kg of raw material. The melting process

requires additionally 1500 MJ of electrical energy, 30 m3 oxygen, 14 kg coke and

38 kg lime5. At the moment almost all electric arc furnaces in Europe are operating

with steel scrap as the charged material.

In order to save carbon emissions in Europe it is reasonable to switch the steel

production from the current situation to a new situation, where no blast furnaces are

in operation anymore. In order to reach this aim the whole European steel production

has to be done by electric furnaces. Assuming that the amount of steel scrap

available cannot be increased significantly, the production of direct reduced ore has

to be enlarged. At the moment only 0.5 million tons of this material are produced in

Europe4. Therefore the production of direct reduced iron has to be increased

significant. For the production of 1 ton of direct reduced iron approx. 1,500 kg ore,

376 m3 of natural gas and 486 MJ of electrical power is need in average in Europe5.

Fig. 39 shows the final energy demand of the steel industry for the three different

switching scenarios. In Fig. 40 the integrated savings of final energy is demonstrated.

It shows the savings for taking the linear and the shock scenario compared with the

reference scenario. By taking the reference scenario the savings would be zero. Fig.

41 displays the associated primary energy of the steel industry. This energy is

calculated from the final energy with the use of the corresponding primary energy

factors described in the paragraph above. Fig. 42 demonstrates the potentials of

savings of primary energy that can be obtained by using the linear or shock scenario.

Fig. 43 displays the progress of the CO2-emission in the steel industry from 2010 till

2050. This is calculated by using the CO2-emission factors presented in the text

above. Fig. 44 shows analogous to the pictures before the possible reduction of CO2-

emission depending on the linear or shock scenario.

It becomes obvious that a switching in the steel production from the blast furnace

process to the production of direct reduced offers big potentials for saving of primary

energy and CO2-emission. By taking the linear scenario instead of the reference

scenario 7.3 million GWh of final energy, 34 million PJ of primary energy and

3.4 billion tons of CO2-emission can be saved. By using the shock scenario instead of

44

the reference scenario it is possible to save 10 million GWh of final energy, 48 million

PJ of primary energy and 4.8 billion tons of CO2-emission.

Fig. 39: Final energy demand for producing steel in the EU-27 from 2010 to 2050

Fig. 40: Saving of final energy for producing steel by using the linear and shock scenario compared of the reference scenario

Fig. 41: Primary energy demand for producing steel in the EU-27 from 2010 to 2050

400.000

410.000

420.000

430.000

440.000

450.000

460.000

470.000

480.000

2010 2020 2030 2040 2050

Fina

l ene

rgy

dem

and

[GW

h]

Reference scenario

Linear scenario

Shock scenario

0

400000

800000

1200000

1600000

2000000

2010 2020 2030 2040 2050

Savi

ng o

f fin

al e

nerg

y [G

Wh]

Linear scenario

Shock scenario

2,000,000

1,600,000

1,200,000

800,000

400,000

0

1.800

1.900

2.000

2.100

2.200

2.300

2.400

2.500

2010 2020 2030 2040 2050

Prim

ary

ener

gy d

eman

d [P

J]

Reference scenario

Linear scenario

Shock scenario

45

Fig. 42: Saving of primary energy for producing steel by using the linear and shock scenario compared of the reference scenario

Fig. 43: CO2-emission for producing steel in the EU-27 from 2010 to 2050

Fig. 44: Saving of CO2-emission for producing steel by using the linear and shock scenario compared of the reference scenario

0.000

1.000

2.000

3.000

4.000

5.000

6.000

7.000

8.000

9.000

2010 2020 2030 2040 2050

Savi

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gy [P

J]

Linear scenario

Shock scenario

0

100

120

140

160

180

200

220

2010 2020 2030 2040 2050

CO2

emis

sion

[Mio

t]

Reference scenario

Linear scenario

Shock scenario

0.000

0.500

1.000

1.500

2.000

2.500

2010 2020 2030 2040 2050

Savi

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io t]

Linear scenario

Shock scenario

0

500

46

4.3.2 Casting grey iron

In the EU-27 in 2007 the yearly production rate of casted grey iron was 13 million

tons. For the fabrication of grey iron a couple of different techniques exist. There a

three oven types that are used for melting namely cupola furnaces, rotary furnaces

and induction furnaces. Each furnace type can be subdivided into some sub-

categories which differ in some process parameters. Despite of this great number of

processes in the EU-27 mainly only two of them are used. This is the hot blast cupola

furnace which is heated with combustibles and the medium frequency induction

crucible furnace which is heated with electrical power. The amount of both processes

is each approximately 50 % of the total amount of casted grey iron7.

The melting of iron with the cupola furnace is based on the principle of countervailing

influence of a shaft furnace. Iron, coke and lime are continuous filled inside the shaft

from above. In the low range of the combustion chamber wind is blown inside to

induce the reaction of the coke with the iron. The special feature of the hot blast

cupola furnace is the preheating of the wind which increases the efficiency. The used

coke is not only the energy supplier for the process but also a reducing agent. With

the help of a siphon the grey iron can be drained continuously. This leads to a

constant quality level of the product but also to an increase of heat losses. For the

production of 1 ton of grey iron 900 kWh of coke, 20 kWh of gas and 30 kWh of

electrical power are needed. Additional 143 kWh are needed for the compensation of

the fire losses7.

The induction crucible furnace is based on a completely different principle of

operation. The induction crucible furnace is based on the mechanisms of the

induction effect. The used frequency of the medium frequency induction crucible

furnace is the range between 150 Hz and 1,000 Hz. For the calculation in this

chapter the averaged and also common frequency of 250 Hz is used. The induction

crucible has some advantages over the cupola furnace. It is possible to melt low-

prized steel scrap. The strong movement of the melt leads to homogenization of the

material and by association to a higher quality. The input energy can be controlled

7 E. Baake, U. Jörn, A. Mühlbauer. 1996. Energiebedarf und CO2-Emission industrieller Prozeßwärmeverfahren. Essen : VULKAN VERLAG, 1996. 3-8027-2912-9.

47

precisely and automated. This leads to a good temperature control inside the

crucible. For the production of 1 ton of grey iron 520 kWh of electrical power are

needed. Additional 48 kWh are needed for the compensation of the fire losses and

74 kWh for the carburization7.

Taking the above numbers into account, the production of 13 million tons of grey iron

consumes 11,000 GWh. It has saving potentials for energy and CO2-emission. The

use of final energy, primary energy, CO2-emission and the integrated savings can be

seen in the following figures. By taking the linear scenario instead of the reference

scenario 53,833 GWh of final energy, 135.6 PJ of primary energy and 48.1 million

tons of CO2-emission can be saved. By using the shock scenario instead of the

reference scenario it is possible to save 74,841 GWh of final energy, 184.5 PJ of

primary energy and 66.6 million tons of CO2-emission.

Fig. 45: Final energy demand for casting grey iron from 2010 to 2050

8.000

8.500

9.000

9.500

10.000

10.500

11.000

11.500

2010 2020 2030 2040 2050

Fina

l ene

rgy

dem

and

[GW

h]

Reference scenario

Linear scenario

Shock scenario

48

Fig. 46: Saving of final energy for casting grey iron by using the linear and shock scenario compared of the reference scenario

Fig. 47: Primary energy demand for casting grey iron from 2010 to 2050

Fig. 48: Saving of primary energy for casting grey iron by using the linear and shock scenario compared of the reference scenario

0

49

Fig. 49: CO2 emission for casting grey iron from 2010 to 2050

Fig. 50: Saving of CO2 emission for casting grey iron by using the linear and shock scenario compared of the reference scenario

50

4.4 Non-ferrous metal industry

4.4.1 Casting copper

In the EU-27 in 2009 the yearly production rate of casted copper and copper-based

alloys was 158 thousand tons8. Compared to the aluminum production this is a

relatively small number. Discussions with some branch experts concluded that

approximately 70 – 90 % of the overall casted copper production was covered by

electro-thermal processes. Especially induction channel furnaces are used to cast

copper. The reason is the relatively high efficiency of induction channel furnaces.

Induction crucible furnaces are frequently used for copper alloys, because they can

be used in batch mode. This is necessary to adjust the correct proportion between

the supplied raw materials. Due to the relatively low installed capacities of fuel

operated processes a switching scenario for the copper production wouldn’t provide

further findings.

8 Modern Casting. December 2010. 44th Census of World Casting Production. December 2010.

51

4.4.2 Casting aluminum

In the EU-27 in 2009 the yearly production rate of casted aluminum was 1.96 million

tons8. Approximately 8 % of the overall production was covered by electro-thermal

processes and 92 % by fuel operated processes9. The electro-thermal processes can

be divided into induction crucible furnaces and induction channel furnaces. The

induction channel furnace is the more common process. A typical induction channel

furnace with an oven capacity of 55 tons needs approximately 415 kWh of electrical

energy7. To replace the fire losses of the aluminum about 200 kWh of electrical

energy is used7. The fuel operated furnaces are mostly rotary furnaces that have a

capacity of about 35 tons7. They are operated with natural gas and have an energy

consumption of approximately 712 kWh7. The fire losses are taken into account with

775 kWh7. These losses are much higher than for the electro-thermal processes.

The use of final energy, primary energy, CO2-emission and the integrated savings

can be seen in the following figures.The production of aluminium has both saving

potentials for energy and CO2-emission. By taking the linear scenario instead of the

reference scenario 32,126.7 GWh of final energy, 104.9 PJ of primary energy and

13.2 million tons of CO2-emission can be saved. By using the shock scenario instead

of the reference scenario it is possible to save 44,677.9 GWh of final energy,

144.8 PJ of primary energy and 18.3 million tons of CO2-emission.

9 Vereinigung Deutscher Schmelzhütten (VDS). 2000. Aluminiumrecycling. Düsseldorf : W.A. Meinke, 2000. 3-00-003839-6.

52

Fig. 51: Final energy demand for casting aluminum from 2010 to 2050

Fig. 52: Saving of final energy for casting aluminum by using the linear and shock scenario compared of the reference scenario

Fig. 53: Primary energy demand for casting aluminum from 2010 to 2050

1.000 1.200 1.400 1.600 1.800 2.000 2.200 2.400 2.600 2.800 3.000

2010 2020 2030 2040 2050

Fina

l ene

rgy

dem

and

[GW

h]

Reference scenario

Linear scenario

Shock scenario

0.000 5.000

10.000 15.000 20.000 25.000 30.000 35.000 40.000 45.000 50.000

2010 2020 2030 2040 2050

Savi

ng o

f fin

al e

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y [G

Wh]

Linear scenario

Shock scenario

0

4

5

6

7

8

9

10

11

12

2010 2020 2030 2040 2050

Prim

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gy d

eman

d [P

J]

Reference scenario

Linear scenario

Shock scenario

53

Fig. 54: Saving of primary energy for casting aluminum by using the linear and shock scenario compared of the reference scenario

Fig. 55: CO2 emission for casting aluminum from 2010 to 2050

Fig. 56: Saving of CO2 emission for casting aluminum by using the linear and shock scenario compared of the reference scenario

0

20

40

60

80

100

120

140

160

2010 2020 2030 2040 2050

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0.2

0.4

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[Mio

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0.8

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2010 2020 2030 2040 2050

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54

4.5 Chemical industry

4.5.1 Plastic production

In the EU-27 in 2007 the yearly plastic production rate was 65 million tons10. For the

fabrication of plastic products mechanical and thermal energy is needed. Mechanical

energy is used for transport processes, for mixing and grinding and for filling and

wrapping applications. Thermal energy is used in large amounts for all kinds of

plastic productions. This heat is mostly produced by electrical energy. In addition

thermal energy is used for drying plastic pellets. Thermal energy is also used for

process steam, which is needed for the Styrofoam production. In the plastic

production the three energy carriers, gas, oil and electrical power are used. In former

times also coal has been used but since the year 2000 this stopped. The rate of gas

is 30%, oil 9 % and the rate of electrical energy is already 61 %11. The specific use of

energy for the plastic production is 1.7 MWh/to 12 . This leads to a final energy

demand of 110,500 GWh.

The use of final energy, primary energy, CO2-emission and the integrated savings

can be seen in the following figures. The production of plastic has saving potentials

of CO2-emission but needs an additional use of primary energy. By taking the linear

scenario instead of the reference scenario 102.6 million tons of CO2-emission can be

saved while 1,245.8 PJ of primary energy has to be used additionally. By using the

shock scenario instead of the reference scenario it is possible to save 138.5 million

tons of CO2-emission while 1,787 PJ of primary energy are needed additionally. The

demand of final energy remains constant for the whole time period and for all

scenarios. Because of this no final energy can be saved.

10 EuPC, EPRO, EuPR and PlasticsEurope. 2008. Daten und Fakten zu Kunststoff 2007. Kunststoffproduktion, Verbrauch und Verwertung in Europa 2007. s.l. : PlasticsEurope, 2008. 11 A. Trautmann, J. Meyer, S. Herpertz. 2002. Rationelle Energienutzung in der Kunststoff verarbeitenden Industrie. Braunschweig/Wiesbaden : Vieweg, 2002. 12 NRW, Landesinitiative Zukunfsenergien. 2002. Rationelle Energienutzung in der Kunststoff verarbeitenden Industrie. Düsseldorf : Landesinitiative Zukunfsenergien, 2002.

55

Fig. 57: Final energy demand for producing plastic from 2010 to 2050

Fig. 58: Saving of final energy for producing plastic by using the linear and shock scenario compared of the reference scenario

Fig. 59: Primary energy demand for producing plastic from 2010 to 2050

110.000 110.100 110.200 110.300 110.400 110.500 110.600 110.700 110.800 110.900 111.000

2010 2020 2030 2040 2050

Fina

l ene

rgy

dem

and

[GW

h]

Reference scenario

Linear scenario

Shock scenario

0 1 2 3 4 5 6 7 8 9

10

2010 2020 2030 2040 2050

Savi

ng o

f fin

al e

nerg

y [G

Wh]

Linear scenario

Shock scenario

56

Fig. 60: Saving of primary energy for producing plastic by using the linear and shock scenario compared of the reference scenario

Fig. 61: CO2 emission for producing plastic from 2010 to 2050

Fig. 62: Saving of CO2 emission for producing plastic by using the linear and shock scenario compared of the reference scenario

-2.000 -1.800 -1.600 -1.400 -1.200 -1.000 -0.800 -0.600 -0.400 -0.200 0.000

2010 2020 2030 2040 2050

Savi

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f prim

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J]

Linear scenario

Shock scenario

-800

-600

-400

0

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57

4.6 Glass, pottery and building materials

4.6.1 Glass industry

In the EU-27 in 2007 the yearly production rate for glass was 37 million tons13. The

specific use of energy for the glass production is about 1.5 MWh/to14. This leads to a

final energy demand of 55.5 TWh. The rate of gas is 34%, oil 46 % and the rate of

electrical energy is 20 %15. The production of glass can be divided into six steps.

They are preparation of the batch, fusing of the batch, contouring, cooling, control of

the quality and finishing. For the preparation of the batch the different components of

the glass are weighted and mixed. The second step of the process, melting of the

batch, is the most energy intensive step, because high temperatures have to be

reached. Afterwards the glass is cooled down to contouring temperature to give the

glass the final shape. Depending on the application range a large number of different

contouring machines are used. The biggest amount of the flat glass production is

manufactured with the float procedure. The melt is passed through a zinc bath to

obtain a flat and high quality glass. Another important procedure is the fabrication of

container or bottle glass which happens in two steps. First the primary form is

produced which will be blown up to the end form in the second step. After contouring

the glass will be cooled down, controlled in quality and maybe also finished and

packed16.

The use of final energy, primary energy, CO2-emission and the integrated savings

can be seen in the following figures. The production of glass has saving potentials

only for CO2-emission. The use of primary energy will increase for both scenarios.

For the linear scenario 128.9 million tons of CO2-emission can be saved and for the

13 European Comission (EC). 2009. Putting Europe´s glass and ceramics industries on the right track. Brussels : s.n., 2009.

14 Glassglobal The glass community. 2009. Mehr Energieeffizienz bei der Glasherstellung. s.l. : VDMA.

15 Bayerisches Landesamt für Umweltschutz (LfU) . 1997. Anlagenbezogene CO2-Minderungspotentiale in der Glasindustrie. München : Bay. St. für Landesent. u. Umweltfragen. 16 Bundesverband Glasindustrie e.V. (BV Glas)

58

shock scenario 174.9 million tons. Compared with this 1,258.3 PJ of additional

primary energy has to be used for the linear scenario and 1,806 PJ of primary energy

for the shock scenario. Final energy cannot be saved, because the demand remains

constant for the whole time period and for all scenarios.

Fig. 63: Final energy demand for producing glass from 2010 to 2050

Fig. 64: Saving of final energy for producing glass by using the linear and shock scenario compared of the reference scenario

55.490 55.492 55.494 55.496 55.498 55.500 55.502 55.504 55.506 55.508 55.510

2010 2020 2030 2040 2050

Fina

l ene

rgy

dem

and

[GW

h]

Reference scenario

Linear scenario

Shock scenario

0 1 2 3 4 5 6 7 8 9

10

2010 2020 2030 2040 2050

Savi

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f fin

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y [G

Wh]

Linear scenario

Shock scenario

59

Fig. 65: Primary energy demand for producing glass from 2010 to 2050

Fig. 66: Saving of primary energy for producing glass by using the linear and shock scenario compared of the reference scenario

Fig. 67: CO2 emission for producing glass from 2010 to 2050

-800 -600 -400

0 -200

60

Fig. 68: Saving of final energy for producing glass by using the linear and shock scenario compared of the reference scenario

61

4.6.2 Brick industry

In the EU-27 the yearly production rate of bricks is about 52.6 million tons17. The

specific use of energy for the brick production is about 551 kWh/to18. This leads to a

final energy demand of 28,976 GWh. The rate of gas is 90 %, oil 2 % and the rate of

electrical energy is 8 %18. In principle bricks consist only of loam and clay. The

production process is energy intensive and simple. In the first step clay and loam are

grinded and mixed. After that the raw material is pressed in an extruder to an endless

line. After cutting into pieces the raw bricks are fired in a tunnel kiln at about 900°C.

The use of final energy, primary energy, CO2-emission and the integrated savings

can be seen in the following figures. The production of bricks has saving potentials of

CO2-emission but needs an additional use of primary energy. By taking the linear

scenario instead of the reference scenario 55 million tons of CO2-emission can be

saved while 779.9 PJ of primary energy has to be used additionally. By using the

shock scenario instead of the reference scenario it is possible to save 74 million tons

of CO2-emission while 1,118.1 PJ of primary energy are needed additionally. There

are no saving possibilities for final energy.

17 Tiles and bricks of Europe (TBE). activated in January 2012. About TBE. [Homepage: http://www.tbe-euro.com/default-en.asp] Bruxelles : s.n., activated in January 2012. 18 Bayerisches Landesamt für Umweltschutz (LfU). 1998. Anlagenbezogene CO2-Minderungspotentiale in der Ziegelindustrie. München : Bayrisches Landesamt für Landesentwicklung und Umweltfragen, 1998

62

Fig. 69: Final energy demand for producing bricks from 2010 to 2050

Fig. 70: Saving of final energy for producing bricks by using the linear and shock scenario compared of the reference scenario

Fig. 71: Primary energy demand for producing bricks from 2010 to 2050

28.971 28.972 28.973 28.974 28.975 28.976 28.977 28.978 28.979 28.980

2010 2020 2030 2040 2050

Fina

l ene

rgy

dem

and

[GW

h]

Reference scenario

Linear scenario

Shock scenario

0 1 2 3 4 5 6 7 8 9

10

2010 2020 2030 2040 2050

Savi

ng o

f fin

al e

nerg

y [G

Wh]

Linear scenario

Shock scenario

63

Fig. 72: Saving of primary energy for producing bricks by using the linear and shock scenario compared of the reference scenario

Fig. 73: CO2 emission for producing bricks from 2010 to 2050

Fig. 74: Saving of final energy for producing bricks by using the linear and shock scenario compared of the reference scenario

-800

-600

-400

0

-200

64

4.6.3 Roof tile industry

In the EU-27 in 2009 the yearly production rate for roof tiles was 9.5 million tons17.

The specific use of energy for the brick production is about 1.105 MWh/to19. This

leads to a final energy demand of 10,493 GWh. The rate of gas is 90 %, the rate of

petroleum products is 0.5 % and the rate of electrical energy is 9.5 %19. The

production of roof tiles is in principle very similar to the brick production. The material

is the same. Only the way of contouring the raw products differs, because most of the

roof tiles cannot be formed with an extruder press. This is a reason why roof tiles are

a bit more energy intensive than bricks. The burning of the roof tiles in the tunnel kiln

is again similar to the brick production.

The use of final energy, primary energy, CO2-emission and the integrated savings

can be seen in the following figures. The production of roof tiles is similar to the brick

production in terms of saving possibilities. By taking the linear scenario instead of the

reference scenario 19.4 million tons of CO2-emission can be saved while 278 PJ of

primary energy has to be used additionally. By using the shock scenario instead of

the reference scenario it is possible to save 26 million tons of CO2-emission while

398.7 PJ of primary energy are needed additionally. There are no saving possibilities

for final energy.

19 Bayerisches Landesamt für Umweltschutz (LfU). 1998. Anlagenbezogene CO2-Minderungspotentiale bei der Dachziegelherstellung. München : Bayerisches Staatsministerium für Landesentwicklung und Umweltfragen, 1998.

65

Fig. 75: Final energy demand for producing roof tiles from 2010 to 2050

Fig. 76: Saving of final energy for producing roof tiles by using the linear and shock scenario compared of the reference scenario

Fig. 77: Primary energy demand for producing roof tiles from 2010 to 2050

10.490

10.491

10.492

10.493

10.494

10.495

2010 2020 2030 2040 2050

Fina

l ene

rgy

dem

and

[GW

h]

Reference scenario

Linear scenario

Shock scenario

0 1 2 3 4 5 6 7 8 9

10

2010 2020 2030 2040 2050

Savi

ng o

f fin

al e

nerg

y [G

Wh]

Linear scenario

Shock scenario

66

Fig. 78: Saving of primary energy for producing roof tiles by using the linear and shock scenario compared of the reference scenario

Fig. 79: CO2 emission for producing roof tiles from 2010 to 2050

Fig. 80: Saving of final energy for producing roof tiles by using the linear and shock scenario compared of the reference scenario

0

0.5

1

1.5

2

2.5

3

2010 2020 2030 2040 2050

CO2

emis

sion

[Mio

to]

Reference scenario

Linear scenario

Shock scenario

0.5

1.5

2.5

67

4.6.4 Cement industry

In the EU-27 in 2008 the yearly production rate for cement was 255,4 million tons20.

The specific use of energy for the cement production is about 867 kWh/to21. This

value is an average over all different oven types for producing lime. This leads to a

final energy demand of 221432 GWh. The rate of petcoke is 41,2 %, coal is 23,6 %,

lignite is 4,3 %, gas is 0,9 %, fuel oil 2,7 %, waste fuels is 15,9 % and the rate of

electrical energy is 11,4 %21. The cement industry is very energy intensive. The basic

material for the cement manufacturing is gained in the stone quarry and contains

limestone, clay, sand and iron ore. The process begins with the decomposition of the

contained calcium carbonate (CaCO3) at about 900 °C. Calcium oxide (CaO, lime)

and carbon dioxide (CO2) leave the CaCO3. This process is also called calcinations.

The next step is the clinkering-process. At high temperatures between 1400°C and

1500 °C the raw material reacts with silica, aluminum, ferrous oxide, aluminates and

ferrites of calcium to a clinker. Afterwards these clinkers are grounded together with

gypsum and other additives21.

The use of final energy, primary energy, CO2-emission and the integrated savings

can be seen in the following figures. The production of cement has saving potentials

of CO2-emission but needs an additional use of primary energy. By taking the linear

scenario instead of the reference scenario 1.6 billion tons of CO2-emission can be

saved while 7,181 PJ of primary energy has to be used additionally. By using the

shock scenario instead of the reference scenario it is possible to save 2.2 billion tons

of CO2-emission while 10,311.7 PJ of primary energy are needed additionally. The

demand of final energy remains constant for the whole time period and for all

scenarios. Because of this no final energy can be saved.

20 Verein Deutscher Zementwerke e.V. (VDZ). May 2011. Zahlen und Daten 2010-2011. Berlin : s.n., May 2011.

21 Umweltbundesamt (German Federal Environment Agency). May 2010. Merkblatt über die Besten Verfügbaren Techniken in der Zement-, Kalk- und Magnesiumoxidindustrie. Dessau : s.n., May 2010.

68

Fig. 81: Final energy demand for producing cement from 2010 to 2050

Fig. 82: Saving of final energy for producing cement by using the linear and shock scenario compared of the reference scenario

Fig. 83: Primary energy demand for producing cement from 2010 to 2050

289.000 289.200 289.400 289.600 289.800 290.000 290.200 290.400 290.600 290.800 291.000

2010 2020 2030 2040 2050

Fina

l ene

rgy

dem

and

[GW

h]

Reference scenario

Linear scenario

Shock scenario

0 1 2 3 4 5 6 7 8 9

10

2010 2020 2030 2040 2050

Savi

ng o

f fin

al e

nerg

y [G

Wh]

Linear scenario

Shock scenario

500

0

69

Fig. 84: Saving of primary energy for producing cement by using the linear and shock scenario compared of the reference scenario

Fig. 85: CO2 emission for producing cement from 2010 to 2050

Fig. 86: Saving of final energy for producing cement by using the linear and shock scenario compared of the reference scenario

0

20

40

60

80

100

120

140

2010 2020 2030 2040 2050

CO2

emis

sion

[Mio

to]

Reference scenario

Linear scenario

Shock scenario

0.000

0.500

1.000

1.500

2.000

2.500

2010 2020 2030 2040 2050

Savi

ng o

f CO

2 em

issi

on [M

io to

] Linear scenario

Shock scenario

-500

0

-500

0

0

70

4.6.5 Lime industry

In the EU-27 in 2006 the yearly production rate for lime was 28 million tons21. The

specific use of energy for the lime production is about 1.3 MWh/to21. This value is an

average over all different oven types for producing lime. This leads to a final energy

demand of 28,976 GWh. The rate of gas is 90 %, oil 2 % and the rate of electrical

energy is 8 %21. The raw material for the lime production is lime stone which is

gained in quarries or mines. The production is similar to the cement production. The

calcium carbonate (CaCO3) in the limestone is calcinated at about 900 °C. The

resulting lime is called quick lime. Together with water the quick lime can be hydrated

and is now called hydrated lime. The hydration is an exothermic reaction.

The use of final energy, primary energy, CO2-emission and the integrated savings

can be seen in the following figures. The production of lime is similar to the cement

production in terms of saving possibilities. By using the linear scenario instead of the

reference scenario 150.2 million tons of CO2-emission can be saved while 1,047.8 PJ

of primary energy has to be used additionally. By using the shock scenario instead of

the reference scenario it is possible to save 205.4 million tons of CO2-emission while

1,502.4 PJ of primary energy are needed additionally. There are no saving

possibilities for final energy.

Fig. 87: Final energy demand for producing lime from 2010 to 2050

36.390

36.395

36.400

36.405

36.410

2010 2020 2030 2040 2050

Fina

l ene

rgy

dem

and

[GW

h]

Reference scenario

Linear scenario

Shock scenario

71

Fig. 88: Saving of final energy for producing lime by using the linear and shock scenario compared of the reference scenario

Fig. 89: energy demand for producing lime from 2010 to 2050

Fig. 90: Saving of primary energy for producing lime by using the linear and shock scenario compared of the reference scenario

0 1 2 3 4 5 6 7 8 9

10

2010 2020 2030 2040 2050

Savi

ng o

f fin

al e

nerg

y [G

Wh]

Linear scenario

Shock scenario

-1.600

-1.400

-1.200

-1.000

-0.800

-0.600

-0.400

-0.200

0.000 2010 2020 2030 2040 2050

Savi

ng o

f prim

ary

ener

gy [P

J]

Linear scenario

Shock scenario

-400

-600

-800

0

-200

72

Fig. 91: CO2 emission for producing lime from 2010 to 2050

Fig. 92: Saving of final energy for producing lime by using the linear and shock scenario compared of the reference scenario

73

4.7 Paper and printing

In the EU-27 in 2009 the yearly production rate for paper, carton and pasteboard was

87.1 million tons22. The process of paper production consists in principle of four

steps. It starts with the pulp production, followed by conditioning and the paper

machine and it ends with the refinement. The pulp production produces single fibers

for the processing. This can be done by recycling old paper or by defibering wood.

For both processes mechanical and thermal energy energy is needed especially for

the comminution. The conditioning process includes suspending, cleaning and

grinding of the pulp, mixing of different types of fibers and the addition of fillers. In the

third production step the paper is produced out on the paper machine. This step is

subdivided into seven, pressing, drying and rolling up the paper web. The seven

machine has the task to spread the raw material on the paper machine in an evenly

way. The first amount of water is removed. In the press the paper web is drained

even more. This is very important, because the more you drain the paper with the

press the less you have to do it with the thermal dryer that is much more energy-

intensive. In the dryer the paper is drained up to a residual moisture of approx. 5-8%.

After this procedure the paper is smoothed and rolled up. The last production step is

the refinement. Here the paper gets coated and satined, depending on the desired

properties. The specific use of energy for the paper production was 2.7 MWh/ton in

the year 200123. This leads to a final energy demand of 200,300 GWh. The rate of

hard coal is 12 %, oil 2 %, gas 42 % and the rate of electrical energy is 30 %23.

The use of final energy, primary energy, CO2-emission and the integrated savings

can be seen in the following figures. The production of paper has saving potentials of

CO2-emission but needs an additional use of primary energy. By taking the linear

scenario instead of the reference scenario 374.4 million tons of CO2-emission can be

saved while 3,814.7 PJ of primary energy has to be used additionally. By using the

shock scenario instead of the reference scenario it is possible to save 508.1 million

22 Verband Deutscher Papierfabriken e. V. (VDP). 2011. Papier Kompass 2011. Bonn : VDP, 2011.

23 Bayerisches Landeramt für Umweltschutz (LfU). 2002. Klimaschutz durch effiziente Energieverwendung in der Papierindustrie. Nutzung von Niedertemperaturabwärme. Augsburg : LfU, 2002.

74

tons of CO2-emission while 5,469.7 PJ of primary energy are needed additionally.

The demand of final energy remains constant for the whole time period and for all

scenarios. Because of this no final energy can be saved.

Fig. 93: Final energy demand for producing paper from 2010 to 2050

Fig. 94: Saving of final energy for producing paper by using the linear and shock scenario compared of the reference scenario

200.000

200.100

200.200

200.300

200.400

200.500

200.600

2010 2020 2030 2040 2050

Fina

l ene

rgy

dem

and

[GW

h]

Reference scenario

Linear scenario

Shock scenario

0 1 2 3 4 5 6 7 8 9

10

2010 2020 2030 2040 2050

Savi

ng o

f fin

al e

nerg

y [G

Wh]

Linear scenario

Shock scenario

75

Fig. 95: Primary energy demand for producing paper from 2010 to 2050

Fig. 96: Saving of primary energy for producing paper by using the linear and shock scenario compared of the reference scenario

Fig. 97: CO2 emission for producing paper from 2010 to 2050

0.400

0.600

0.800

1.000

1.200

1.400

1.600

2010 2020 2030 2040 2050

Prim

ary

ener

gy d

eman

d [P

J]

Reference scenario

Linear scenario

Shock scenario

400

600

800

-6.000

-5.000

-4.000

-3.000

-2.000

-1.000

0.000 2010 2020 2030 2040 2050

Savi

ng o

f prim

ary

ener

gy [P

J]

Linear scenario

Shock scenario

0

76

Fig. 98: Saving of final energy for producing paper by using the linear and shock scenario compared of the reference scenario

77

5. Conclusion

The work in hand makes clear that a switching of fuel operated industrial processes

to electro-thermal processes offers big potentials for saving of primary energy and

CO2-emission. Altogether five energy intensive industrial branches have been

analysed with the help of case studies. These five industry sectors ordered by the

final energy demand in 2009 are the chemical industry with 585,896 GWh, the iron

and steel industry with 514,848.47 GWh, the glass, pottery and building material

industry with 424,832.27 GWh, the paper and printing industry with 384,115.64 GWh

and the non-ferrous metal industry with 103,681.45 GWh.

In the year 2010 the calculated final energy demand for the plastic production was

110,500 GWh. This covers about 18.8 % of the chemical industry. The calculated

final energy demand for the steel production was 434,923 GWh and 10,972 GWh for

the production of grey iron. Consequently the sum of 445,904 GWh covers about

86.6 % of the full iron and steel industry. The final energy demand for the glass

production is 55,500 GWh, for the roof tile production 10,493 GWh, 28,976 GWh for

the brick production, 289,907 GWh for the cement production and 36,400 GWh for

the lime production. The sum of 421,275 GWh covers about 99 % of the glass,

pottery and building material industry. The final energy for producing paper was

calculated with 200,299 GWh that covers 52 % of the overall paper and printing

industry. The production of casted aluminum needs about 2,774 GWh of energy that

covers 2.7 % of the complete non-ferrous metal industry.

Table 3 summarizes the share of the calculated final energy demand on the overall

final energy demand of the five different branches. The table gives an overview how

much the case studies cover the overall energy demand. Table 4 summarizes the

yearly savings respectively the additional yearly amounts of final energy, primary

energy and CO2-emission that can be achieved after the year 2050. This year marks

the point when a complete switching to EPM technologies is realized. As shown in

the table 4 all together 67,512.66 GWh of final energy can be saved yearly in the ten

regarded industry sectors. This means a decrease of 13.7 %. In terms of primary

78

energy the saving per year after 2050 is 210.29 PJ which connotes to a decrease of

4.1 %. The most substantial saving can be achieved with CO2-emission. 246.56

million tons of CO2-emission can be saved yearly which is related to a decrease of

63.4 %.

It is remarkable that the consumption of primary energy increases for all industry

sectors except the Iron & Steel industry and the NF metals industry. The reason for

this additional effort of primary energy can be explained with the particular primary

energy factor. The PEF for electrical power is higher than the PEF´s for other energy

carriers like coke, natural gas, lignite and petroleum products. This is status of today

and it will still be the case in the year 2050. The steel and NF-metal industry will

achieve a decrease in the primary energy consumption in spite of that. The reason is

that here the process is completely changed in particular the physical heating

principle. In the grey iron industry for example a switching from a coke fired cupola

furnace to an induction furnace is realized. The induction furnace has a high

efficiency and needs much less final energy than the cupola furnace which leads to

savings of final energy as well as primary energy consequently. In the other branches

(Chemical, Glass, pottery & building materials and Paper & printing) the complete

process, in particular the physical principal of the heating process, is not changed but

only the energy carrier. This has no significant effect on the demand of final energy.

Table 5 summarizes the integrated savings respectively additional amounts of final

energy, primary energy and CO2-emission that can be achieved in the time period

from 2010 to 2050. It is obvious that the savings depend on the chosen scenario.

79

Branch Industry sector

Calculated final energy demand

in 2010

Final energy demand of the branch

Share

Chemical Plastic 110,500

Sum 110,500 585,896 19 %

Iron & steel Steel 434,923

Grey iron 10,972

Sum 445,904 514,848 87 %

Glass, pottery &

building materials

Glass 55,500

Roof tile 10,493

Brick 28,976

Cement 289,907

Lime 36,400

Sum 421,275 424,832 99 %

Paper & printing Paper 200,299

Sum 200,299 384,116 52 %

NF metals Aluminum 2,774

Sum 2,774 103,681 3 %

Table 3: Share of the calculated final energy demands on the overall energy demand of the five different branches.

80

CO

2-em

issi

on

%

68.7

39.5

77.1

83.4

82.3

82.7

90.5

88.8

80.3

77.2

63.4

Mill

ion

tons

8.93

74.7

0

2.63

10.3

3

1.81

5.11

101.

61

10.5

9

30.1

4

0,71

246.

56

Prim

ary

ener

gy

%

-2.3

14.1

23.0

-4.3

-6.0

-6.1

-4.3

-6.6

-4.2

54.,9

4.1

PJ

-10.

35*

315.

71

10.2

1

-9.4

3

-2.4

5

-6.8

5

-49.

80

-9.2

5

-33.

49

5.99

210.

29

Fina

l ene

rgy %

0

13.2

23.9

0 0 0 0 0 0

56.5

13.7

GW

h

0

63,3

19.0

2

2626

.00

0 0 0 0 0 0

1567

.64

67,5

12.6

6

Indu

stry

se

ctor

Pla

stic

Ste

el

Gre

y iro

n

Gla

ss

Roo

f tile

Bric

k

Cem

ent

Lim

e

Pap

er

Alu

min

um

Sum

Bra

nch

Che

mic

al

Iron

& s

teel

Gla

ss, p

otte

ry &

bu

ildin

g m

ater

ials

Pap

er &

prin

ting

Non

-ferro

us

met

als

Table 4: Savings of final energy, primary energy and CO2-emission per year after 2050 (* Negative numbers imply an additional effort).

81

Savi

ng p

oten

tials

for u

sing

the

shoc

k sc

enar

io C

O2-

emis

sion

Mill

ion

tons

138.

5

2,03

9.9

66.6

175.

0

26.0

73.9

2,20

4.6

205.

4

508.

1

18.3

5,45

6.3

Prim

ary

ener

gy

PJ

-1,7

86.9

7,85

2.2

184.

5

-1,8

06.0

-398

.7

-1,1

18.1

-10,

311.

7

-1,5

02.4

-5,4

69.7

144.

8

-14,

212

Fina

l en

ergy

GW

h

0

1,80

4,59

1.2

74,8

41

0 0 0 0 0 0

44,6

77.9

1,92

4,11

0.8

Savi

ng p

oten

tials

for u

sing

the

linea

r sce

nario

CO

2-em

issi

on

Mill

ion

tons

102.

6

1,46

9.6

48.1

128.

9

19.4

55.0

1,60

3.5

150.

2

374.

4

13.3

3,96

5.0

Prim

ary

ener

gy

PJ

-1,2

45.8

*

5,67

8.5

135.

6

-1,2

58.3

-278

.0

-779

.8

-7,1

81.5

-1,0

47.8

-3,8

14.7

104.

9

-9,6

86.9

Fina

l en

ergy

GW

h

0

1,29

8,03

9.8

53,8

33

0 0 0 0 0 0

32,1

36.7

1,38

4,00

9.5

Indu

stry

se

ctor

Pla

stic

Ste

el

Gre

y iro

n

Gla

ss

Roo

f tile

Bric

k

Cem

ent

Lim

e

Pap

er

Alu

min

um

Sum

Bra

nch

Che

mic

al

Iron

& s

teel

Gla

ss, p

otte

ry &

bu

ildin

g m

ater

ials

Pap

er &

prin

ting

Non

-ferro

us

met

als

Table 5: Savings of final energy, primary energy and CO2-emission for the two the different industry sectors for both switching scenarios (* Negative numbers imply an additional effort).

82

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